Casting mold



June. 16, 1925.

C. D. PETTIS CASTING Mom) Filed May 7 1925 6 Sheets-Sheet l June 16,1925.

c. D. PTl-lsI CASTING MOLD Filed May '7. 1925` 6 SheetS-Sheet 2 V @img@uw ffm@ MMOM @MW/J June 16, 1925.

C. D. PETTIS` CASTING MOLD Filed May '7. 1925 6 Sheetsrsheet 5 June 16,1925. 1,542,637

c. D. PETTls CASTING MOLD Filed May 7 1923 6 sneetslsheet 4 Y ZZLUQRUW:

June 16,- 1925. 1,542,637

C. D. PETTIS CASTING MOLD Filed May v. 192s s sheets-sheet 5 6Sheets-Sheet 6 C. D. PETTIS cAsTING MOLD Filed May '7, 192s June 16,1925.

l uw* Patented June 16, 1925.

CLIFTON D. PETTIS, OF NEW YORK, N. Y.

CASTING MOLD.

Application med my 7, 1923. serai m. 637,165.

To all whom it 'ntay concern:

Be it known that I, CLIFTON D. PETTIS, a

citizen of the United States, residing in struction and which may bequickly and eas- Y the line 4 4 of Fig. 2.

ily operated to provide a large output.

Further objects of my invention are to reduce the number of. parts ofthe mold, to facilitate the cooling of the casting, to eliminate theusual cope member of the mold, to facilitate the inclusion of chills inthe mold, vand in general to provide a new and improved moldconstruction.

The .many other objects and advantages of my invention will be betterunderstood by reference to the following specilication when consideredin connection with the accompanying drawings illustrating certainselected embodiments thereof, in which:-' Fig. 1 is a side elevation ofthe casting mold complete with the parts in closed position.

.2 is the same as Fig. 1, plan view. Fig. 3 1 s the same as Fig. 1, endelevation. Flg. 4 1s a transverse vertical section on Fig. 5 'is avertical longitudinal section on the line 5-5 of Fig. 2.

Fig. 6 is the same as Fig. 5, inpart, show.

ing the steel shell in position in the mold.

Fig. 7 is the same as Fig. 4, in' art, showing the steel shellinposition in t e mold.

Figs; 8 to 16 ,ae detail views. Fig. 17 is a plan View of one type ofsteel shell., I

Fig. 18l is a centrallongi'tudinal section of the steel shell shown inFig. 17.

Fig. 19 is a plan view of a modified form Fig.20 isa section on the line20--20 of Fig. 19.y

Fig. 21 is a transverse vertical section on the line 21-21g0f Fig. 20.

'preferably of metal.

Fig. 22 is apartialsection on the line 22-22 0f Fig. 19.

Figs. 23 to 25' inclusive are detail views of amodied form of pouringgate, and

Fig. 26 is a detail view of another modilied form of pouring gate.

Referring tothe drawings, it will be seen that the particular designs ofcasting molds which' I have selected to illustrate the principles of myinvention are intended for'the casting of railway brake shoes but itshould be clearly understood that these principles are equallyapplicable to molds for casting many other articles.

Referring particularly to Figs. 1 to 18 inclusive, the mold is mountedupon a suitable base A of cast metal and comprises a plurality ofseparable sections or members forming a flask or holder, each membercarrying a corresponding part, of vthe molding receptacle. provided withupstanding box-shaped supports 30 which are perforated to receive thecorresponding ends of a pivot rod 33. This pivot rod 33 passes throughlugs 34 depending from the bottom of movable side members B, B of themold. A stationary botx tom member C is mounted on these supports?- 30between the side members B, B.

In the present embodiment of my inven tion each of the members B and Cincludes 'a metal frame or flask ffsection, the outeri walls of themembers B being preferably perforated, as at' 35, to provideventilation.' Chambers, as 36, in these Vmembers permit free circulationof air about the molding receptacle, to be presently described.

The walls of the molding receptaclefwith the exception of a portion ofthe top comprise a plurality of -blocks arranged in groups or sections,each section being carried bythe corresponding ilask section. At

the portions ofthe receptacle whereit is desired to chill the casting,these blocks are The remaining blocks arefpreferably formed of somehighly refractory material, such .as carborundum,

To this end the base A is4 lse that may be readily molded into thedesired form. All blocks would preferably be of refractory material whenno chilligof the casting is required. The blocks are' assembled in theseveral sections or members composing the holding frame or ilaskrwithsuiicient spacing between the blocks of Va section to permit expansionbut insuicient to allow 'the molten metal to flow into the interstices.

The frame or flask of the base section C in the present embodimentcomprises end pieces 40.formed integral with the supports 30 andconnected by a plate 41. Refractory blocks D are mounted in this flasksection and held in place by a key or guard plate 42 which is attachedto the end pieces 40 by screws 43 or other suitable means. The plates 41and 42 are each provided witlra rib, as 44, which fits within acorresponding groove in the blocks D.` The end blocks are cut away, asat 45, to substantially fit the correspondin corners on the flask (Fig.5). Boxes or hol ers, as 46, are provided on the ends of the baselsection C of the flask to receive blocks E which form the ends of themolding receptacle. These blocks E in the present embodiment are ofmetal to chill the end portions of the casting. Projections 47 on 'thebases of these blocks enter corresponding sockets inthe bottom walls ofthe holders 46 to properly position the blocks therein. The under blocksD are preferably directly exposed to the atmosphere tofacilitatevcooling.

Blocks F in the side lmembers B, B of,

the mold are placed Within the flask sections through openings in 4theouter side walls of these sections and retained therein by key or guardplates 50 which are secured to the sections byscrews 51 or othersuitable lneans. The top plates of the members B, B are preferablyprovided with depending flanges 52 which fit within correspondingindentations in the blocks. Similarly upstanding flanges 53 are providedupon the inner edges of the base plates of these members. In order tosupport the blocks F at an interval from the base walls of the members,I have provided.

ribs or projections 54. This provides an air chamber beneath the blocksfor the free circulation of air. Ribs or projections 55 on the plates 50perform 'a like function. The flanges 53 preferably contact with theplates 41 and 42 in the bottom section C when the side members are movedto closed position in the manner which will be presently described, andthus protect the blocks D and F from impact and possible injury. Boxedsections 56 are provided at the ends of the side members B, B to hold inposition chill blocks G, G and H, H, the inner faces of these sectionsbeing provided with taperin ribs, as at 57, to hold these chill blocks1n proper position longitudinally, also to prevent them from rising whenthe molten metal is poured into the casting chamber. These ribs exert aWedge action on the chill blocks and thus firmly hold together theblocks at each end of the mold. The blocks G, G are alike except thattheir form is reversed. Blocks H, H are alike in the same manner.

faces of the A `pair of upstanding lugs 60 is provided on the base A oneach side of the mold and each pair supports a pivot rod 61. A sleeve 62is mounted on each of these rods between the lugs and this sleevecarries a pair of eccentrically mounted rollers or cams. 63. Lugs 64 onthe side Wall of the members l are disposed above and below each ofthese rollers or cams. An operating lever 65 is formed on or attached toeach sleeve so that when these levers are raised, the side menibers Bwill be swung on the-pivot rod 33 to closed position. Similarly when thelevers are depressed, these side members will be moved to openposi-tion.

One of the lower chill blocks E is shown in :detail in Figs. 8 to 10inclusive, Fig. 8 being a side elevation, Fig. 9 a bottom plan view, andFig. l() an end elevation. A portion of the molding cavity 66 isincluded in this block and the portion of the brake shoe casting formedtherein is chilled. .It will thus be seen that this block chills the endof the shoe and also the end portion of the sides and face. l

In addition to acting as chills the blocks G perform the functions ofpouring gate and mold for one end lug.' One of these blocks is Shown indetail in Figs. 11 to 13 inclusive, Fig. 11 being a side elevation, Fig.12 a bottom plan view, and Fig. 13 an end elevation. A channel 67 isformed between these blocks and the molten metal enters the castingchamber therethrough. The end lug is formed in the cavity 68, one-halfof the cavity being in each block as in the case of the pouring gatechannel.

The upper chill blocks H perform the same functions as the blocks Gexcept that of acting as a pouring gate. One of these blocks is shown'indetail in Figs. 14 to 16, Fig. 14 being a side elevation, Fig. 15 abottom iplan view, and Fig. 16` an end elevation. The end lug is formedin the cavity 69 corresponding to the cavity 68 in the block G. Theupper chillblocks G each rest on the lower chill block E and the uppersurface of the steel brake shoe shell 71 (Fig: 5). The chill blocks Hlikewise rest on the lower chill block E and the steel brake shoe shell71. Where no chilling of the casting is required, refractory blocks oflike form would be substituted for these chill blocks.

Shoulders 70 are formed on the end chill blocks E to support a steelbrake shoe shell, as 71 and maintain this shell in proper verticalposition. In the present embodiment, this shell forms the top wall ofthe molding receptacle and is held in place upon the shoulders 70 by theblocks G and H. This shell preferably has no openings provided in itstop Wall except a pouring opening 72 and end lug openings 73. When thebrake shoe is to be provided with steel end lugs attached to the shell,as distinguished from cast lugs,` no endlug openings would be providedin the shell. This steel end lug construction may be used in the presentmold as the steel lugs will enter the cavities 68 and 69 inthe blocks Gand H. 4As steel lugs of this type are well known in the art, no

, illustration or detail `description is neces- \sary. The molten metalenters the perforalthe mold and the chill blocks tions, as 74, in theside and end walls of the shell and firmly incorporates the shell in thecasting. In the present embodiment, the center lug 75 is formed ofductile metal and attached to the shell by flanges 76 projecting throughthe shell and bent inwardly beneath the top wall thereof. The pouringopening 72 is preferably larger than the corresponding openings in theblocks to prevent the inflowing molten metal from fusing the shell. Onthe other hand, the end lug openings 73 are preferably smaller than theopenings in the blocks so as to anchor the end lug to the body metal ofthe shoe. The chill blocks G and H are preferably tapered,

vas at 77 and 78 respectively, so that when the side members B areopened and closed there is no scraping action. These chill blocks G andH may bemade in different vertical thicknesses to permit the manufactureof steel shell brake shoes of varying thickness and without changing anyof the other parts of the mold.

In the operation of this mold, it is placed in open position, that isthe handles are moved downwardly, thus withdrawing the side members Bfrom contact with the stationary base member C. The end chill blocks Eare then laced in their respective holders. The steel shell, as 71, isnext placed in the mold with its ends resting on the shoulders providedfor the purpose. The chill blocks G are then placed on top of thecorresponding block E at one end of -I similarly placed at the oppositeend. Th side members B`are then moved to closed position by the levers65 and the molten metal poured into the channel in the pouring gateuntil the mold is filled. After the metal has sufliciently hardened, themembers B are moved to open position, leaving the finished castingresting on the refractory blocks of the stationary members C of the moldand with all of the chill blocks in the same position as placed whenpreparing the mold. The brake shoe with all chill blocks surrounding theends is now removed from the mold and placed in a proper place to cool.The mold is nowz made ready for another pouring by inserting another setof chill blocks', the set just used being too hot to properly chill thenext casting. When the finished shoe cools the chill blocksdrop awayfrom it-as with chilled shoes cast inordnary sand molds. Whenthe chillblocks have cooled suiiciently they may be again used. A distinctadvantage in having the chill blocks and pouring gate combined is thatthe deterioration from successive pourings through a cast metal pouringgate lwhile still hot is avoided. The metal is only poured through thegate when the chill blocks are cold. By having the end chills G and Hseparated no diliculty results from shrinkage ofthe shoe longitudinallywhich would otherwisev tend to produce a binding action and causetrouble in getting the shoe from the mold.

It will be obvious that this mold is exceedingly simple in construction,consisting of but two movable members, the stationary base member andthe refractory and chill blocks. No cope, end members, or cores needbeused. The design of steel shell brake shoe having perforations along-the sides and ends, enables very satisfactory venting through theseperforations and the spaces between the refractory blocks. With thesection of the steel shell on each side of the center lug exposed to theatmosphere and with the superior venting provided, the shoe will coolmuch more rapidly than sand- Imolded shoes.

It will be noted that there is no scraping action whatever in theoperation of the mold nor in the removal of the shoe from the mold. Itshould also be noted that none of the refractories have any depressionsm them, all of them presenting only flat or im -members of the mold.Each of these end members in the present embodiment comprises achambered flaskv section 102 in which are mounted refractory blocks 103.These blocks are held in place within the section by a key or guardplate 104 which is secured to the section by screws 105 or othersuitable means. The steel shell 71 is placed within the mold in the samemanner as was described in connection with the previous embodiment andrests on shoulders 106 formed in the faces o-f the refractory/'blocks inthe end members.- The end membersI are moved to closed position andI theshell placed with its ends resting on the shoulders 70. After theinsertion of the shell, combined pouring gate and end lug mold 107is-thenplaced at one end of the shell and the end lugl moldv 110 at theother end. The side members are then moved to closed position whereuponribs 109 on holder 108 firmly hold and position this pouring gate. Thecombined pouring gate and end lug mold 107 in the present embodiment isformed of burnt or hard sand. The end lug mold 110 at the opposite endof the mold proper is also formed of hard or burnt sand and rests uponthe steel shell 71. This mold 110 is held in position thereon bytriangular ribs 111 (Fig. 22) formed on the side members B. These ribsfit Within corresponding depressions in the end lug mold.

The end members M of the mold are preferably tapered, as at 112, ontheir inner faces to prevent any scraping action 'when the mold isopened. The end faces of the side members B are shaped to conform. Atthe completion of 'the molding operation, the end members are firstmoved to open position and then the side members are likewise moved. Theparts 107 and 110 remain on the casting and are knocked off when thelatter is lifted from the mold.

In Figs. 23 to 25 inclusive is shown a modified form of pouring gate foruse with the mold construction shown in Figs. 19 to 22, Fig. 23 being aplan view. Fig. 24 a central vertical section, and Fig. 25 an end vleW.This construction comprises a metal box 115 adapted to receive a filling116 of green sand which is molded with a pouring hole 117 and end lugcavity 118. -This metal box may be repeatedly used with new fillings.The filled box is placed in the mold proper and held therein in themanner dcscrlbed for the burnt sand gate 107 in the previous embodiment.i

Fig. 26 shows a section of a box 119 similar to that shown in Fig. 24,except that thls box is intended for use with a steel shell constructionin which steel end lugs are attached to this shell. No mold cavity forthe end lug is thereforeInecessary in the green sand filling. A similarcavity 120 to admit the steel lug is, however, provided by an extensionof the lend wall of the box.

I am aware that numerous changes in the form and arrangement of parts ofmy mold may be made by anyone skilled in the art without departing fromthe spirit of my invention and I reserve the right to make all such asfairly fall within the scope of the vfollowing claims.

I claim as my invention:

1. A casting mold comprising a betteln sectlon, relatively movable sidesections, and a metal plate adapted to be supported by 'certain of saidsections and to form with saidl sections a molding receptacle when saidsections are in closed position.

2. casting mold comprising a bottom section, relatively movable sidesections, end sections carried by said bottom section,

and a metal shell adapted to be supported by certain of said sectionsand to orln .withy said sections a molding receptacle when said sectionsare in closed position.

3. A casting mold comprising a bottom member, relatively movable sidemembers, blocks carried by each of said members, and a metal shelladapted to be supported by certain of said members and to form with saidblocks a molding receptacle when said members are in closed'position.

4. A casting mold comprising a bottom member, relatively movable sidemembers, end members carried by said bottom members, blocks mounted ineach of said members, and a metal shell adapted to be supported bycertain ot' said members when said members are in closed position and toform with said blocks a molding receptacle.

5. In a casting mold, a molding receptacle comprising a plurality otsections arranged to form thebottom, side and end walls thereof', and ametal plate adapted to be supported by said sections and to form the topwall of said receptacle, certain of said sections being formed of aplurality of separate blocks.

In a casting mold, a molding receptacle comprising aplurality ofseparable sections arranged to form a portion of said receptacle, and ametal shell forming the remaining portion of said receptacle, certain ofsaid sections being formed of a plurality of separate blocks.

7. In a casting mold, z.. molding receptacle comprising a plurality ofsections arranged to form a portion of said receptacle, and a metalshell forming the remaining portion of said receptacle, certain of saidsections being formed of a plurality of refractory blocks.

8. In a casting mold, a molding receptacle comprising a plurality ofrelatively movable sections formlng a portion of said receptacle, and aseparable metal shell forming the remaining portion of said receptacle,each of. said sections comprising a plurality of blocks securedtogether.

9. In a casting mold, a molding receptacle comprising a plurality ofsections arranged to form the bottom, side and end walls of saidreceptacle, and a metal member forming the top of said receptacle andbeing adapted to be incorporated in the casting when the mold isfilled,l certain of said sections being formed of a plurality ofseparate blocks.

10. In a casting mold, a molding receptacle comprising a bottom section,end sections, movable side sections, and a top section adapted to restupon said end sections and to be held in lace thereon by said sidesections when saidpside sections are in closed position.

11. In a casting mold, a molding receptacle comprising bottom and sidesections, each including a plurality of separate blocks, end sections,and a spaced metal plate forming the top section of said receptacle.

12. In a casting mold, a molding re ceptacle having an opening in itstop, and a separable metal late, forming the closure for said top andbeing provided with a pouring passage, said late being adapted to beincorporated in tliecasting when the mold is filled.

13. In acasting mold, a molding receptacle open at the top, a separablemetal plate forming the top of said receptacle and being rovided with apouring passage said plate eing adapted to be incorporate in thecasting, and a pouring gate adapted to be securedto said plate wlth itspouring passage communicating with the passage in said plate.

14. In --al casting mold, a moldin receptacle open at the top andcomprislng a plurality of sections, certain of which are movable, ametal late formin the top of said receptacle an being provided with apouring passage, and a pourin gate secured upon said plate by certain othe movable /sections of said receptacle when said sections are inclosed position, the pourin passage in said gate communicating witg thepassage in sai plate.

15. Ina casting mold, a molding receptacle open at the top andcomprising a plurality of sections, certain of which are movable, aseparate metal shell fitting within said receptacle and forming aclosure A therefor, said shell .being provided with a pouring passage,and a pouring ate of refractory material adapted to be c amped upon saidshell by the movable sections of said receptacle when Asaid sections aremoved to closed position, the pouring passage in said gate. beingadapted to communicate with a corresponding passage throu h said shell.

16. n a casting mold, a molding receptacle comprising end sections, sidesections cooperating with said end sections, certain of said sectionsbeing movable, and a top section adapted to rest on certain of saidsections and to be clamped in position thereon by certain other sectionsby the moving of said other sections to closed position.

17. .In a casting mold, a molding receptacle comprising end sectionsmovable side sections cooperating with said end sections, and a topsection and pouring gate section adapted to be clamped in osition bysaid side sections when said side sections are :moved to closedposition, said pourin gate 18. In a casting mold, a molding receptaclecomprising a bottom section, end sections, movable side sectionscooperating with said bottom and end sections, a top section adapted torest on certain of said ections, and a pouring gate adapted to rest nsaid top section andcommunicate withl the casting chamber inV saidreceptacle through a passage in said top section, said top section andsaid pouring gate being clamped in position by said side sections.' whensaid side sections are brought to closed position.-

19. In a casting mold, a molding receptacle open at the top, a separatemetal plate forming a closure-for said top and havlng a pouring passagetherein, and a pouring gate mounted on said plate with its pouringpassage forming acontinuation of the passage in said plate, the passagein said plate being of greater area than the immediately adjacentportion of the passage in said ate to prevent. the iniowing moltenmetircontacting with said plate.

20. A mold for casting brake shoesy comprising a base, bottom, end andside mold sections mounted on said base, and -a metal back adapted torest upon certain of said sections and to be held in position thereon bycertain other-sections to form with said sections a moldin receptacle,nsaid back bein incorporated lnto the casting when the mol is filled.

` 21. A mold for casting brake shoes comprising a plurality of separablemold seotions co-operating to form the bottom, side and end walls of themold, and a metal shell within the mold and held against removalthereby, said shell forming a portion of the top wall of the mold andbeing constructed to become interloclged with the casting when the moldis filled;

22. A mold for casting brake shoes comprising a plurality ofseparablemold s tions co-operatin to form the bottom, si e and end wallso the mold, and ar ductile metal shell adapted to rest upon saidsections and to be held in position thereon by said sections to form thetop Wall of the mold, said shell being constructed to become interlockedwith the casting when the mold is filled. .l

23. A mold for casting brake shoes comprising a plurality of separablemold s ections co-operating to form the bottom, side and end walls ofthe mold, and a an-shaped of said mold, said shell being constructed tobecome interlocked with the casting when the mold is filled.

24. In a casting mold, the combination `with a sectional ask of moldingreceptacle sections carried by the corresponding sections osaid flask,frame members on certain of said flask sections cooperating to form apouring gate holder, and blocks supported b lsaid sections and held inposition thereon y said frame members when said sections are in closedposition, said blocks co-o erating to form the pouring gate of the mol25. In a casting mold, the combination with a sectional iask of moldingreceptacle \sections carried by the corresponding sections of saidflask,frame members on certain of said flask sections co-operating to form apouring gate holder, and chill blocks supported by said sections andheld in position thereon by said frame members when said sections are inclosed position,said blocks being clamped in position on said flask bythe moving of the iask sections to closed position and co-operating toform the pouring gate of the mold.

26. In a casting mold, a molding receptacle comprising a plurality ofseparable sections arranged to form a portion of said receptacle, and ametal shell forming at least a portion of the remainder of saidreceptacle, certain of said sections being formed of a plurality ofseparate blocks.

27. In a casting mold, a molding receptacle comprising a plurality ofsections arranged to form a ortion of said receptacle, and a metal shellorming at least a portion of the remainder of said receptacle, certainof said sections being formed of a plurality of refractory blocks.

28. In a casting mold, a molding receptacle having portions thereofformed by readily separable self-supporting blocks, and a metal shelldetachably supported by said blocks and forming another portion of themolding receptacle.

29. In a casting mold, a molding receptacle having bottom, end and sidewalls, a metal shell supported thereby and adapted to form the top wallof the molding receptacle, said metal shell having a pouring opening anda pouring gate cooperating With said opening.

30. As an article of manufacture, a mold constructed at least in part ofrelatively movable sections adapted to expand or contract whilemaintaining a molding receptacle of substantially constant overalldimensions, and a metal plate cooperating with said sections and forminganother portion of the molding receptacle.

31. As an article of manufacture, a mold constructed at least in part ofrelatively movable sections adapted to expand or contract whilemaintaining a molding receptacle of substantially constant overalldimensions, a metal plate cooperating with said sections and forminganother portion of the moldin receptacle, said plate being adapted toecome incorporated in the finished casting.

32. As an article of manufacture, a mold having a molding receptacleformed in part by a plurality of relatively movable sections and in partby a metallic plate cooperating therewith and adapted to becomeincorporated in the finished casting.

33. As an article of manufacture, a mold having a molding receptacleformed in part by a plurality of relatively movable -sections and inpart by a metallic plate cooperating therewith and adapted to becomeincorporated in the finished casting, said sections being supported forseparation about predetermined axes.

34,. As an article of manufacture, a molding receptacle formed in partby a plurality of spaced blocks and in part by a metallic platecooperating therewith and adapted to ecome incorporated in a finishedcastin CLIFTON D. PETTI

